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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1327 (Rear Drive Axle) >> Repair Instructions >> Differential Carrier Cover and Seal Replacement - Right >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Differential Cover (Right) & Bolts
    GM334840Courtesy of GENERAL MOTORS CORP.
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the RH rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  3. Remove the RH wheel drive shaft. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  4. Remove the RH muffler assembly. Refer to Muffler Replacement - Right in Engine Exhaust.
  5. Drain the fluid from the differential. Refer to Lubricant Change .
  6. Clean any dirt or debris from around the differential cover (right).
  7. Remove the bolts retaining the differential cover (right).
  8. Remove the transmission vent tube retainer (automatic transmission).
  9. Remove the differential cover (right) from the differential.
    10. Fig 2: Differential Cover (Right), Axle Seal & O-Ring Seal
    GM58038Courtesy of GENERAL MOTORS CORP.
  10. Remove and discard the axle seal (1), and O-ring seal (4) from the differential cover (right).
    11. Fig 3: Differential Cover (Right) & J 42194
    GM63600Courtesy of GENERAL MOTORS CORP.
  11. Install the J 42194  into the differential cover (right), in order to remove the bearing race and shims. See Special Tools and Equipment . Position the cover into a hydraulic press.
    12. Fig 4: Bearing Race & Shims
    GM354444Courtesy of GENERAL MOTORS CORP.
  12. Using a hydraulic press, remove the bearing race (1) and shims (2). Mark or tag the shims for assembly.
    13. Fig 5: Measuring Differential Cover Bore Dimension
    GM893553Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Whenever service requires the replacement of the right side differential cover, the covers MUST be measured and the right side shim pack adjusted to compensate for machining tolerances between the two components. Failure to perform this measurement procedure may result in improper differential bearing preload.
  13. Use a caliper (2), a straight edge (1), and J 42168-16  (3) in order to measure the NEW differential cover bore dimension. See Special Tools and Equipment . Record the measurement as value A.
  14. Use a caliper (2), a straight edge (1), and J 42168-16  (3) in order to measure the old differential cover bore dimension. See Special Tools and Equipment . Record the measurement as value B.
  15. Subtract value B from value A. If the computation is a positive value, add shims equal to the value, to the existing shim pack. If the computation is a negative value, subtract shims equal to the value, from the existing shim pack.
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